Axial flux machine

Abstract

An axial flux machine includes a modulated stator, a rotor, and a plurality of spacers. The modulated stator includes plural stator units. Each stator unit includes a magnetic core and at least one winding. The magnetic core has first plate, a second plate, and a sidewall connecting the first plate to the second plate, and the winding is disposed on the magnetic core. The stator units construct the modulated stator. By modulating the stator, the slot fill factor and the cogging torque performance can be improved. The spacers are disposed to isolate the magnetic cores. The rotor is disposed in the modulated stator and includes plural first magnetic pieces and second magnetic pieces arranged alternately, and the magnetic flux lines of the first and second magnetic pieces respectively pass through sidewalls of the magnetic cores to construct C-type magnetic loops of opposite directions thereby improving power density.

What is claimed is: 
     
       1. An axial flux machine comprising:
 a modulated stator comprising a plurality of stator units, each of the stator unit comprising:
 a first magnetic core comprising a first plate and a first sidewall, wherein a first end of the first plate is connected to a first end of the first sidewall, and a cross-section of the first magnetic core is L-shaped; 
 a first winding disposed in the first magnetic core; 
 a second magnetic core comprising a second plate and a second sidewall, wherein a first end of the second plate is connected to a first end of the second sidewall, and a cross-section of the second magnetic core is L-shaped, wherein a second end of the first sidewall is physically in contact with a second end of the second sidewall; and 
 a second winding disposed in the second magnetic core; 
 
 a plurality of spacers disposed to isolate the first magnetic cores and to isolate the second magnetic cores; and 
 a rotor disposed between the first magnetic core and the second magnetic core, the rotor comprising a plurality of first magnetic pieces and a plurality of second magnetic pieces arranged alternately, wherein magnetic flux lines of the first magnetic pieces and the second magnetic pieces respectively pass through the first sidewall and the second sidewall to construct a plurality of C-type magnetic loops with opposite magnetic directions. 
 
     
     
       2. The axial flux machine of  claim 1 , wherein the C-type magnetic loops comprise the magnetic flux lines of the first magnetic pieces and the second magnetic pieces, wherein
 the magnetic flux lines of the first magnetic pieces are emitted from a top surface of the first magnetic pieces and sequentially pass through the first winding, the first plate, the first sidewall, the second sidewall, the second plate, and the second winding, and return to a bottom surface of the first magnetic pieces; and 
 the magnetic flux lines of the second magnetic pieces are emitted from a bottom surface of the second magnetic pieces and sequentially pass through the second winding, the second plate, the second sidewall, the first sidewall, the first plate, and the first winding, and return to a top surface of the second magnetic pieces. 
 
     
     
       3. The axial flux machine of  claim 1 , wherein the first winding and the second winding respectively comprise:
 a coil rack bonded on the first plate or the second plate; and 
 a plurality of coils, wherein the coils are wound on the coil rack after the coil rack is bonded on the first plate or the second plate. 
 
     
     
       4. The axial flux machine of  claim 3 , wherein the first magnetic core and the second magnetic core respectively comprise:
 a tooth disposed on the first plate or the second plate to position the coil rack; and 
 a shoe coupled to the tooth. 
 
     
     
       5. The axial flux machine of  claim 1 , wherein the first winding and the second winding respectively comprise a coil rack and a plurality of coils, wherein the first magnetic core and the second magnetic core respectively comprise:
 a tooth disposed on the first plate or the second plate, wherein the coil rack is detachably coupled to the tooth after the coils are wound on the coil rack; and 
 a shoe coupled to the tooth for fastening the coil rack. 
 
     
     
       6. An axial flux machine comprising:
 a modulated stator comprising a plurality of stator units, each of the stator units comprising:
 a magnetic core comprising a first plate, a second plate, and a sidewall connecting the first plate to the second plate, wherein the first plate is substantially parallel to the second plate; and 
 at least one winding disposed in the magnetic core; and 
 
 a plurality of spacers disposed to isolate the magnetic cores; and 
 a rotor disposed in the modulated stator, the rotor comprising a plurality of first magnetic pieces and a plurality of second magnetic pieces arranged alternately, wherein magnetic flux lines of the first magnetic pieces and the second magnetic pieces respectively pass through the sidewall to construct a plurality of C-type magnetic loops with opposite magnetic directions. 
 
     
     
       7. The axial flux machine of  claim 6 , wherein the C-type magnetic loops comprise the magnetic flux lines of the first magnetic pieces and the second magnetic pieces, wherein
 the magnetic flux lines of the first magnetic pieces are emitted from a top surface of the first magnetic pieces and sequentially pass through the first plate, the sidewall, and the second plate, and return to a bottom surface of the first magnetic pieces; and 
 the magnetic flux lines of the second magnetic pieces are emitted from a bottom surface of the second magnetic pieces and sequentially pass through the second plate, the sidewall, and the first plate, and return to a top surface of the second magnetic pieces. 
 
     
     
       8. The axial flux machine of  claim 6 , wherein the winding comprises:
 a coil rack bonded on the first plate or the second plate; and 
 a plurality of coils, wherein the coils are wound on the coil rack after the coil rack is bonded on the first plate or the second plate. 
 
     
     
       9. The axial flux machine of  claim 8 , wherein the magnetic core comprises:
 a tooth disposed on the first plate or the second plate to position the coil rack; and 
 a shoe coupled to the tooth. 
 
     
     
       10. The axial flux machine of  claim 6 , wherein the winding comprises a coil rack and a plurality of coils, wherein the magnetic core comprises:
 a tooth disposed on the first plate or the second plate, wherein the coil rack is detachably coupled to the tooth after the coils are wound on the coil rack; and 
 a shoe coupled to the tooth for fastening the coil rack.